Thermally insulating packaging

ABSTRACT

A thermally insulating packaging to hold an item includes a solid compostable or recyclable shell that is formed primarily of starch, and a bottom cover. The shell includes a floor, a plurality of inner side walls that are coupled to the floor, a rim coupled to the plurality of inner side walls, and a plurality of outer side walls that are couple to the rim. The floor and the plurality of inner side walls define an interior space of the shell to receive the item and an opening to the interior space. The plurality of inner side walls and plurality of outer side walls have a space therebetween that defines a gap. The gap can be an air-filled cavity, or be filled with a compostable or recyclable core material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/904,168, filed Feb. 23, 2018, which claims the benefit of U.S.Provisional Application Ser. No. 62/462,842, filed Feb. 23, 2017, andU.S. Provisional Application Ser. No. 62/467,705, filed Mar. 6, 2017,the disclosures of which are incorporated by reference.

TECHNICAL FIELD

This invention relates to a thermally insulating packaging.

BACKGROUND

A conventional container for shipping temperature sensitive productsincludes a cardboard box, inside of which is a thermally insulatingmaterial. A conventional thermally insulating material is expandedpolystyrene (EPS), e.g., Styrofoam. For example, panels formed ofexpanded polystyrene can line the walls of the box, and another packingmaterial, e.g., bubble wrap, can be placed surround and cushion the itembeing shipped inside the panels. Alternatively, expanded polystyrene canbe machined or molded to form a “cooler” into which the item beingshipped can be placed—this does not need an external box. In eithercase, a coolant, e.g., ice, dry ice or a gel pack, is placed in thecavity in the box with the item being shipped.

EPS is relatively inexpensive and easily formed into a variety ofshapes, but is not compostable. Consequently, disposing of the materialof the container can be a problem.

SUMMARY

Packaging is described that provides for thermal insulation of an itembeing shipped while the components of the packaging are still recyclableor compostable.

In general, in one aspect, a thermally insulating packaging to hold anitem includes a solid compostable or recyclable shell that is formedprimarily of a starch, and a bottom cover. The shell includes a floor, aplurality of inner side walls that are coupled to the floor, a rimcoupled to the plurality of inner side walls, and a plurality of outerside walls that are coupled to the rim. The floor and the plurality ofinner side walls define an interior space of the shell to receive theitem and an opening to the interior space. The plurality of inner sidewalls and plurality of outer side walls have a space therebetween thatdefines a first gap. The floor is continuously coupled to each of theplurality of inner side walls, each of the plurality of inner side wallsis continuously coupled to adjacent inner side walls, each of theplurality of inner side walls is continuously coupled to the rim, therim is continuously coupled to each of the plurality of outer sidewalls, and each of the plurality of outer side walls is continuouslycoupled to adjacent outer side walls. The bottom cover is attached tobottom edges of the outer walls of the shell and extends below the floorof the shell. The floor and the bottom cover having a space therebetweenthat defines a second gap. The floor, the plurality of inner side walls,the rim, the plurality of outer side walls and the bottom cover definean air-filled cavity that includes the first gap and the second gap. Theair-filled cavity and shell are sufficiently thick to provide thermalinsulation.

The foregoing and other implementations can each optionally include oneor more of the following features, alone or in combination.

The shell may be formed primarily a grain starch, a root starch, avegetable starch, or combinations thereof. A first water-proof,water-resistant or water-repellant layer may be disposed on the shelland configured to block water penetrating the shell. The shell mayinclude a first water-proof, water-resistant or water-repellant materialmixed with the starch. The shell may consist of the material and thestarch.

A thickness of the cavity may be between ¼ and 4 inches. A thickness ofthe shell may be between 0.02 and 0.3 inches.

The bottom cover may include a flap extending off a bottom edge of theouter side wall of the shell. The bottom cover may be a separate cover.The bottom cover may be secured to the shell with an adhesive to sealair in the cavity.

In another aspect, a thermally insulating packaging to hold an itemincludes a solid compostable or recyclable shell that is formedprimarily of a first material that is a starch, and a compostable orrecyclable core formed of a different second that is a starch, a plantfiber, a plastic, or a combination thereof. The shell includes a floor,a plurality of inner side walls that are coupled to the floor, a rimcoupled to the plurality of inner side walls, and a plurality of outerside walls that are coupled to the rim. The floor and the plurality ofinner side walls define an interior space of the shell to receive theitem and an opening to the interior space. The plurality of inner sidewalls and plurality of outer side walls have a space therebetween thatdefines a gap. The floor is continuously coupled to each of theplurality of inner side walls, each of the plurality of inner side wallsis continuously coupled to adjacent inner side walls, each of theplurality of inner side walls is continuously coupled to the rim, therim is continuously coupled to each of the plurality of outer sidewalls, and each of the plurality of outer side walls is continuouslycoupled to adjacent outer side walls. The compostable or recyclable coreis positioned in the first gap. The core and shell are sufficientlythick to provide thermal insulation.

The foregoing and other implementations can each optionally include oneor more of the following features, alone or in combination.

A first water-proof, water-resistant or water-repellant layer may bedisposed on the shell and may be configured to block water penetratingthe shell. The shell may include a first water-proof, water-resistant orwater-repellant material mixed with the plant fiber.

A thickness of the core may be between ¼ and 4 inches. A thickness ofthe shell may be between 0.02 and 0.3 inches

The core may extend below the floor of the shell. A bottom cover may beattached to bottom edges of the outer walls of the shell and may extendbelow the floor of the shell.

The core may be a solid panel or loose-fill material. The core may besecured in the gap.

The shell may be formed primarily from a grain starch, a root starch, avegetable starch, or combinations thereof. The second material mayinclude a plant fiber, e.g., coconut husk, corn husk, linen, cotton, orcombinations thereof.

The foregoing and other implementations can each optionally include oneor more of the following features, alone or in combination.

The thermally insulating packaging may include a second solidcompostable or recyclable body. The second solid compostable orrecyclable body may include: a second floor, one or more secondprojections that are located on a surface of the second floor and thatinclude one or more second grooves to hold a second portion of the item,a plurality of second inner side walls that are coupled to the secondfloor, a second rim that is coupled to the plurality of second innerside walls, and a plurality of second outer side walls that are coupledto the second rim. The second floor and the plurality of second innerside walls may define a second interior space. The second floor, theplurality of second inner side walls, the second rim, the plurality ofsecond outer side walls may define a second space within the secondsolid compostable or recyclable body. The second floor may becontinuously coupled to each of the plurality of second inner sidewalls, each of the plurality of second inner side walls may becontinuously coupled to adjacent second inner side walls, each of theplurality of second inner side walls may be continuously coupled to thesecond rim, the second rim may be continuously coupled to each of theplurality of second outer side walls, and each of the plurality ofsecond outer side walls may be continuously coupled to adjacent secondouter side walls. The second solid compostable or recyclable body andthe second space may be sufficiently thick to provide thermalinsulation.

The plurality of first outer side walls may be coupled to the pluralityof second outer side walls such that the first interior space of thefirst solid compostable or recyclable body is enclosed by the secondsolid compostable or recyclable body. The first solid compostable orrecyclable body may further include first protrusions that are locatedon the first rim. The second solid compostable or recyclable body mayinclude second grooves that are located on the second rims. The firstprotrusions may be inserted into the second grooves. The first solidcompostable or recyclable body may further include first protrusionsthat are located on the first rim, the second solid compostable orrecyclable body may include second protrusions that are located on thesecond rims, and the first protrusions may be coupled to the secondprotrusions.

The first solid compostable or recyclable body may further include oneor more pads that are located on a surface of the first floor. Thethermally insulating packaging may further include a cover that enclosesthe first cavity and that is primarily formed of a compostable orrecyclable material.

At least one of the plurality of first outer side walls may include agroove on an outer surface of the first outer side wall that isconfigured to be gripped by a user to carry the thermally insulatingpackaging. The first solid compostable or recyclable body may furtherinclude a spacer that protrudes from a first outer side wall of theplurality of first outer side walls.

The item may be a bottle including a first end, a second end, and abottle body that connects the first end to the second end. The one ormore first grooves of the first solid compostable or recyclable body mayhave a circular shape such that each of the one or more first grooves isconfigured to hold the first end of the bottle. The one or more firstgrooves of the first solid compostable or recyclable body may have abottle shape such that each of the one or more first grooves isconfigured to hold at least a portion of the bottle body of the bottle.The one or more first grooves of the first solid compostable orrecyclable body may have a rectangular shape such that each of the oneor more first grooves is configured to hold the item. At least one ofthe plurality of first outer side walls may include a groove on an innersurface of the first outer side wall that is configured to hold a coolerpackage.

The thermally insulating packaging may further include a water-proof,water-resistant, or water-repellant layer that, fully or in part,encloses the first solid compostable or recyclable body and that isconfigured to inhibit water from penetrating the layer. The water-proof,water-resistant, or water-repellant layer may be sprayed onto the firstsolid compostable or recyclable body. The first solid compostable orrecyclable body may have a uniform thickness. The thickness of the firstsolid compostable or recyclable body may be between 0.5 and 5 inches.The compostable material may include a grain starch, a root starch, avegetable starch, or combinations thereof. The compostable material maybe a plant fiber. The plant fiber may be coconut husk, corn husk, linen,or cotton or paper, or combinations thereof. The first solid compostableor recyclable body may be stackable on top of the second solidcompostable or recyclable body.

Potential advantages may include (and are not limited to) one or more ofthe following. The thermally insulating packaging is compostable orrecyclable, so all of the components of the thermally insulatingpackaging are easily disposable. If present, the layer, in part orfully, enclosing the insulating material is compostable or recyclable,and also easily disposed. The thermally insulating packaging can store acooling package to maintain the interior space of the thermallyinsulating packaging at a particular temperature so an item can bestored freshly. The thermally insulating packaging can provideequivalent thermal insulation to expanded polystyrene, and can bedisposed in commercial and residential composting or recycling bins orgarbage cans.

The details of one or more embodiments are set forth in the accompanyingdrawings and the description below. Other features, objects, andadvantages of the invention will be apparent from the description anddrawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1A is an exploded perspective view of a first implementation of athermally insulating packaging.

FIG. 1B is a cross-sectional view of the first implementation of athermally insulating packaging.

FIG. 1C is a cross-sectional view of a second implementation of athermally insulating packaging.

FIG. 1D is a cross-sectional view of a third implementation of athermally insulating packaging.

FIG. 1E is a bottom view of a floor of a fourth implementation of athermally insulating packaging.

FIGS. 1F to 1M are perspective views of implementations of a thermallyinsulating packaging.

FIG. 1N is a perspective view of an implementation of thermallyinsulating packaging in which package has two sub-compartments.

FIG. 1O is a cross-sectional view through a horizontal plane of FIG. 1N.

FIG. 2A is a perspective view of a first implementation of a pair ofthermally insulating articles that form a shipping package.

FIG. 2B is a cross-sectional view of the pair of thermally insulatingarticles of FIG. 2A.

FIG. 2C is a perspective view of a second implementation of a set ofthermally insulating articles that form a shipping package.

FIG. 2D is a cross-sectional view of a first implementation of the setof thermally insulating articles of FIG. 2C.

FIG. 2E is a cross-sectional view of a second implementation of the setof thermally insulating articles of FIG. 2C.

FIG. 3A is a perspective view of a second implementation of a pair ofthermally insulating articles that form a shipping package.

FIGS. 3B and 3C are cross-sectional views of the pair of thermallyinsulating articles of FIG. 3A.

FIG. 3D is a cross-sectional view of a third implementation of a pair ofthermally insulating articles.

FIG. 4A is a perspective view of a fourth implementation of a pair ofthermally insulating articles that form a shipping package.

FIG. 4B is a cross-sectional view of the pair of thermally insulatingarticles of FIG. 4A.

FIGS. 5A to 5D are cross-sectional views of implementations of a coverfor thermally insulating packaging.

FIG. 6 is a diagram illustrating an example system to manufacture thethermally insulating packaging of FIG. 1A.

FIGS. 7A to 7C are cross-sectional views of implementations of astackable compostable or recyclable body.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Initially, some terminology may be beneficial. “Biodegradable” simplymeans that a product will eventually disintegrate into to innocuousmaterial. “Recyclable” indicates that a product can be reused or treatedin order to be made suitable for reuse. “Compostable” indicates boththat a product will decompose quickly, e.g., within 180 days, and thatthe product will decompose into material that can be used as fertilizer(e.g., per ASTM D6400 or EN 13432). Products that are “biodegradable”need not be (and usually aren't) “compostable.” First, since there is noparticular time limit for a “biodegradable” product to disintegrate, itneed not decompose quickly. For example, even aluminum cans willbiodegrade given several centuries. Moreover, even a biodegradableproduct that decomposes quickly might not provide a material that issuitable as fertilizer.

Most conventional thermally insulating materials for packaging, e.g.,EPS, are not compostable. One technique for using a compostableinsulating packaging material is to fill a volume between an inner walland an outer wall of a box with loose-fill compostable cornstarch foampellets (e.g., packing “peanuts”) using layered stratification, and thencompress each layer of foam pellets in within this volume to compactthem. This technique requires either multiple boxes or a specialized boxhaving both inner and outer walls, and also requires specializedmachinery for layered stratification compaction of the pellets. Theadditional or specialized boxes increase the cost. In addition, theloose fill pellets are difficult to compost because they are messy whenremoved from the box. Moreover, a large amount of pressure, e.g., 25lbs. or more, needs to be applied to close the top flaps of the box dueto the resistance from the pellets.

However, instead of loose-fill foam pellets, a solid compostable orrecyclable body formed primarily of a starch, e.g., milled extrudedsorghum or corn starch, organic fibers, e.g., paper or corn husk fiber,or a plastic, e.g., polyethylene, provides a thermally insulatingpackaging for shipping an item, and this packaging can be used as theinsulation in the container.

The solid compostable or recyclable body can be a single-piece body, orit can be a shell that surrounds a core of compostable or recyclablematerial, or it can be a shell that encloses an air-filled cavity.

The solid compostable or recyclable body can be enclosed by or coatedwith a biodegradable or recyclable layer. The layer can provide amoisture barrier. The layer can be a water-proof, water-resistant orwater-repellant layer. In addition, a water-proof, water-resistant orwater-repellant material can be mixed with the extruded starch or plantfiber to protect the body from moisture.

Structure of Thermally Insulating Packaging

FIG. 1A is an exploded perspective view of a first implementation of athermally insulating packaging. FIG. 1B is a cross-sectional view of thefirst implementation of the thermally insulating packaging in FIG. 1A.In some implementations, the thermally insulating packaging 100 can beshipped without being inserted into a shipping box; in this case thepackaging 100 can serve as the shipping container. In some otherimplementations, the thermally insulating packaging 100 can be insertedinto a shipping box, e.g., a cardboard box, for shipping.

The thermally insulating packaging 100 includes a solid compostable orrecyclable body 110 that is primarily formed of a compostable and/orrecyclable material. In this context, “solid” indicates that the body110 holds together as a single unit, e.g., rather than being formed ofloose-fill pellets. The thermally insulating packaging 100 canoptionally include a water-proof, water-resistant or water-repellantlayer that covers at least a portion of the body 110.

Examples of the compostable material(s) for forming the body 110 arestarch, organic fibers, or a combination of them. The starch can be agrain starch, e.g., a corn starch, a wheat starch or sorghum (sorghum isalso known as milo), a root starch, e.g., a potato starch, or avegetable starch. In some cases, a combinations of different starchescan be used. The starch can be formed into the body 110 by an extrusionprocess.

The organic fiber can be a plant fiber, e.g., a wood fiber or avegetable fiber. For example, the plant fibers could be fibers fromcoconut husk, corn husk, linen, or cotton. In some cases, a combinationof plant fibers from different plants can be used. The organic fiber canbe formed into the body 110 by mixing fibers into a pulp, e.g., a paperpulp or pulp of vegetable fibers, and then extruding the pulp orcompressing the pulp in a mold. Where the body is formed from a paperpulp, the body can be considered to be formed of paper, e.g., acardboard material.

An example of the recyclable material for forming the body 110 is aplastic, e.g., polyethylene. For example, the body 110 can includelow-density polyethylene (LDPE), medium-density polyethylene (MDPE),high-density polyethylene (HDPE), or polyethylene terephthalate. In someimplementations, polyethylene can be shredded into particles having aparticular size or a random size and be compacted to form the body 110.An advantage of polyethylene is ease of fabrication and good waterresistance.

Another example of recyclable material for the body 110 is organicfiber, e.g., plant fiber, such as paper (whether paper is compostable orrecyclable can depend on the thickness, size and porosity of the body).As noted above, the organic fiber can be formed into the body 110 bymixing fibers into a pulp, e.g., paper pulp or pulp of vegetable fibers,and then extruding the pulp or compressing the pulp in a mold.

In some implementations, the body 110 consists of starch. In someimplementations, the body consists of plant fiber. In some cases, acombination of starch and plant fiber can be used; the body can consistof starch and plant fiber.

In some implementations, a moisture barrier material to increaseresistance of the body 110 to water can be mixed with the starch and/ororganic fiber. The material can be mixed with the starch or fiber whileit is liquid form, e.g., with the fiber pulp, and then harden in thebody. Whether the resulting material of the body 110 is water-proof,water-resistant or water-repellant can depend on the concentration ofthe material. In some implementations the material can be polylacticacid (PLA). In some implementations, the body 110 consists of starchand/or plant fiber, in combination with the moisture barrier material.

Other materials that do not interfere with the compostable or recyclablenature of the body 110, e.g., a softener to improve adhesion of thestarch, or a preservative or anti-fungal agent, can be present, but onlyin small quantities. For example, at least 85%, e.g., at least 90-95%,by weight of the body 110 is starch and/or pulp. Polyvinyl alcohol canbe present, e.g., 5-10% by weight.

In some implementations, the body 110 is entirely compostable, i.e.,consists of compostable materials. In some implementations, the body 110is entirely recyclable, i.e., consists of recyclable materials. In someimplementations, the body 110 is formed of a combination of compostableand recyclable materials.

In some implementations, the material of the body 110 can be a foammaterial, e.g., to include small pores or voids spread substantiallyuniformly through the body 110. For example, 10-80% of the volume of thebody 111 can be pores or voids, e.g., 25-75%, 25-50%, 10-25%, 50-75%.The maximum size of the pores or voids can be about 1 mm. Although thebody 110 could be a foam material, it is generally incompressible. Thedensity of the solid compostable or recyclable body 110 can be about0.4-3.5 g/cm³, e.g., 0.6-1.0 g/cm³, 0.8-2.0 g/cm³, 1.0-3.5 g/cm³.

The thickness of the body 110 can be about 0.5-5 inches, e.g., 1-3inches. Any given unitary body 110 can have substantially uniformthickness. The floor 140, the outer side walls 160, and the inner sidewalls 170 can have substantially uniform thickness. In someimplementations, the surfaces of the body 110 can be generally flat. Insome other implementations, one or more surfaces of the body 110 can becorrugated. Corrugation can increase the effective thickness of the body110, e.g., by a factor of up to 4. In this case, the thickness of thebody 110 can still be uniform, but the body 110 is shaped withcorrugations. However, in some implementations, the inner surfaces ofthe body have various projections, e.g., tabs or struts, e.g., to assistin positioning of the item to be shipped or for increased structuralsupport. In some implementations, the inner surfaces of the body havevarious projections, e.g., tabs or struts, e.g., to assist inpositioning of the item to be shipped or for increased structuralsupport. In addition, in some implementations, the outer surfaces of thebody can have various projections, e.g., pads or struts, e.g., to assistprovide increased structural support or cushioning.

Referring a top view of the thermally insulating packaging 100 shown inFIG. 1A, the thermally insulating packaging 100 generally takes the formof a “tub,” e.g., a container with floor and side-walls and that is openat the top and has an interior space 112. The “tub” can have box-likeshape, e.g., a generally rectilinear prism. Of course, the edges of thebody can be rounded, while remaining a generally rectilinear prism. Inaddition, the “tub” could have other shapes, e.g., octagonal,cylindrical, etc., while still considered to have side-walls.

In some implementations, the interior space 112 can have a square shape.In some other implementations, the interior area 112 can have arectangular shape. In some other implementations, the interior area 112can have a circular shape.

Referring FIGS. 1B, 1D and 1I, the body 110 is or includes a unitarylayer that provides at least a floor 140 and side walls 160 for theinterior space 112 of the body 110. This unitary layer is “continuous.”In this context, “continuous” indicates that the portions are joinedwithout a discontinuity in material composition; there is no gap,adhesive, melted region, or similar disruption in the materialcomposition to indicate a seam between floor and walls or betweenadjacent walls. This unitary layer holds together by itself as a singleunit without adhesives or fasteners to join multiple sections.

The solid compostable or recyclable body 110 can have a uniformhomogenous composition. The solid compostable or recyclable body 110 canbe primarily formed of a single compostable or recyclable material.

As shown in FIGS. 1B and 1D, the packaging 100 can be a single-piecebody, i.e., the solid compostable or recyclable body 110 consists of,i.e., is only, the unitary layer. As a unitary layer, the floor 140 ofthe solid compostable or recyclable body 110 is joined “continuously” tothe side walls 160 along edges 161. In addition, each of the side walls160 is joined “continuously” to its adjacent side walls along edges,e.g., an edge 161.

As shown in FIGS. 1B and 1I, the unitary layer of the body can form ashell with a gap between inner side walls 160 that provide the sidewalls of the interior space 112 and outer side walls 170 that providethe side walls of the exterior of the packaging. Together, the innerside wall and outer side walls can provide the side walls of thepackaging.

Alternatively, as shown in FIG. 1D, the body doesn't include anyinterior cavity between the inside surface and outside surface of theside walls of the packaging. In this case, the side walls 160 canprovide both the inside surface (that provides the interior space) andthe outside surface of the packaging. The body 110 can be of continuousbetween the inside surface and outside surface of the side walls 160.The body 110 can be of homogenous composition between the inside surfaceand outside surface of the side walls.

For any of the various implementations, although the floor and walls ofthe body 110 can be thin, as compared to their respective length andwidth, the floor and walls are thick enough to provide sufficientthermal insulating function for common commercial applications thatrequire shipment by package delivery service, e.g., FedEx or UPSservices, of packages, e.g., up to 48″×48″×48″, of products, e.g., foodsor medical supplies, that need to be kept cool, e.g., at temperatures of32-48° F. In general, this can be accomplished with the body 110 havinga thicknesses noted above, e.g., of about 0.5-5 inches for asingle-piece compostable body. For a body including a shell, thethickness can be 0.25-4 inches for the core or air gap, and 0.01 to 0.75inch (0.25-18 mm), e.g. 0.02 to 0.3 inches (0.5-7.5 mm), e.g., 0.02 to0.1 inches (0.5-2.5 mm) for the shell. In some implementations, theshell is between 1/32 and 1 inch thick.

An example thickness t1 of the solid compostable or recyclable body 110can be 0.5-5 inches. In some implementations, e.g., the illustratedexample of FIG. 1D, the solid compostable or recyclable body 110 hassubstantially uniform thickness. In some implementations, the solidcompostable or recyclable body 110 can have non-uniform thickness. Forexample, a thickness of the floor 140 can be different from a thicknessfor the side wall 160. A width w1 of the interior space 112 can be 3-48inches.

In the example of the body 110 in FIGS. 1A, 1B and 1I, the floor 140 iscontinuously joined to the inner side walls 160. Each of the inner sidewalls 160 is joined “continuously” to its adjacent inner side wallsalong edges. The inner side walls 160 are also continuously jointed tothe outer side walls 170 by a rim 165 of the body 110. Each of the outerside walls 170 is joined “continuously” to its adjacent outer side wallsalong edges.

In the example of the body 110 in FIGS. 1B and 1I, the floor 140, theinner side walls 160, the rims 165, the outer side walls 170 define acavity 180 within the body 110. The gap between the inner side wall 160and the outer side wall 170 can be 0.5-4 inches.

In some implementations, e.g., referring to FIG. 1B, the cavity 180 canbe left as an empty space, e.g., an air gap. The bottom of the thermallyinsulating packaging 100 is closed off by a lower cover 120 to enclosethe space.

In some implementations, e.g., referring to FIG. 1I, a compostable orrecyclable material(s) is placed in the cavity 180. In this case, thebody 110 includes both a shell (formed from the body described above)and material that fits into the cavity 180 in the shell and thatprovides a core 182 of the body. The cavity 180 can be filled with thecompostable or recyclable material(s). Optionally, the bottom of thethermally insulating packaging 100 is closed off by a lower cover 120 tocover the core 182 of the body 110.

An example thickness t1 of the core 182 can be 0.25-4 inches. An examplethickness t2 of the outer side walls 160, the rims 165, and the innersidewalls 170 can be 0.125-0.5 inches.

In some illustrated examples, e.g., FIG. 1I, the body 110 hassubstantially uniform thickness. The inner side walls 160, rims 165, andouter side walls 170 have a uniform thickness. In some implementations,the body 110 can have non-uniform thickness. For example, thicknesses ofthe inner side walls 160, rims 165, and outer side walls 170 can bedifferent from each other. A width w1 of the interior space 112 can be3-48 inches. In addition, as described below, the interior and/orexterior surfaces of the body 110 can have protrusions and/or recesses.

In some implementations, the shell and the core can have differentcompositions. For example, the shell can be primarily formed of starch,e.g., corn starch, whereas the core can be primarily formed of organicfiber, e.g., paper. As another example, the shell can be primarilyformed of organic fiber, e.g., paper, whereas the core is primarilyformed of starch, e.g., corn starch.

As another example, the shell can be primarily formed of a first kind ofstarch, e.g., a grain starch, such as corn starch, while the core can beprimarily formed of a second kind of starch, e.g., a root starch orvegetable starch, or another grain starch, such as sorghum. As anotherexample, the shell can be primarily formed of a first kind of plantfiber, e.g., paper, while the core can be primarily formed of a secondkind of plant fiber, e.g., a vegetable fiber, such as corn husk fiber.In these examples, both the shell and the core are compostable andrecyclable.

As another example, the shell can be primarily formed of starch or plantfiber, and the core can be primarily formed of a recyclable plastic,e.g., polyethylene. For example, the plastic can be in a shredded orpellet form, e.g., shredded polyethylene or polyethylene pellets. Inthis example, the shell is compostable and recyclable while the core isrecyclable. As another example, the core can be primarily formed ofstarch or plant fiber, and the shell can be primarily formed ofpolyethylene. In this example, the core is compostable and recyclablewhile the shell is recyclable. In these implementations, even if theshell has a composition that is different from a composition of thecore, each of the shell and the core can have a uniform homogenouscomposition.

In some implementations, the shell and the core can have the samecomposition, but the composition of the shell and the composition of thecore can be differently processed. For example, both the shell and thecore can be primarily formed of a starch. However, the starch used forthe shell can be processed at a first temperature during a dryingprocess while the starch used for the core can be processed at a secondtemperature during a drying process.

In some implementations, the shell and the core can have differentfirmness. For example, the shell can be primarily formed of a materialthat is harder than the material that provides the core, or vice versa.Alternatively, the shell and the core can have the same firmness.

In some implementations, e.g., as shown in FIG. 1F, the shell is a solidbody but the core is loose material, e.g., pellets, shredded material,powder, etc. For example, the core can be composed of starch pellets,shredded paper, loose plant fibers, etc.

In some implementations, both the shell and the core are solid bodies,but the core is slidable within the cavity 180 between the inside sidewall 160 and the outside side wall 170. For example, the core can beprovided by one or more solid panels that fit into the cavities. Suchsolid panels can be formed by an extrusion process, e.g., extrusion of astarch, or by a compaction process, e.g., compaction of a plant fiberpulp. In some implementations, there is a separate panel for each sideof the body 110, with each panel independently slidable within thecavity 180. Optionally another panel may be positioned below the floor140. Thus, there can be four (or five) panels for the rectilinear tubshape of the packaging 100. In some implementations, the core caninclude a multi-part panel, e.g., a panel that is folded into anappropriate shape and then inserted into the cavity 180. For example,the core can be provided by a single a multi-part panel, e.g., a stripthat is folded into a collar and inserted into the cavity 180, or across-shape that is folded and inserted into the cavity such that eacharm of the cross fits into one side wall and the center of the cross ispositioned below the floor 140.

In some implementations, the core is effectively fixed inside the shell.For example, the core can include a solid body that is friction fit orsecured with adhesive to the interior surfaces of the shell. As anotherexample, loose material, e.g., pellets, shredded material, or powder,can be compacted within the cavity 180 to an extent that the loosematerial is wedged inside the shell.

If the core is loose or slidable within the cavity 180, the bottom ofthe shell will need to be covered, e.g., by the lower cover 120, toretain the loose material of the core within the shell. The cover 120can partially compact the loose material within the cavity 180. However,the compaction need not be to an extent that the loose material iswedged inside the shell.

If the core is a solid body or is a loose material that is sufficientlycompacted that it can't be trivially dislodged, then covering the bottomof the shell is optional; a portion of the shell can extend across thebottom of the core to enclose the core, or the bottom of the core couldprovide the lower outer surface of the body 110.

In some other implementations, e.g., as shown in FIG. 1B, the cavity 180can be filled with air, that is the cavity 180 can be left as an emptyspace. In this case, the bottom of the shell can be covered to enclosethe air within the cavity 180. For example, as shown in FIGS. 1B, 1I,1J, and 1L, a separate cover 120 can be secured to the bottom edges ofthe outer walls of the shell. As another example, as shown in FIGS. 1C,1K and 1M, the shell can includes one or more flaps 162 that are foldedinward to enclose the cavity 180. The bottom cover, either as a separatecover 120 or flaps 162, can be attached to the shell with adhesive toseal the air within the cavity.

In some implementations, support pieces can be placed between the floor140 of the shell and the cover 120 or flaps 162 to prevent collapse ofthe floor 140 when weight is placed in the interior 112.

The inner side walls 170 can have a height (in the vertical direction)smaller, e.g., by about 0.5 to 4 inches, than the height of the outerside walls 160. This permits a gap to be formed between the lower cover120 and the floor 140 when the lower cover 120 is attached to the body110. Alternatively, the bottom of the floor 140 could be coplanar withthe bottom of the outer side walls 160; in this case there would not bea gap below the floor 140 when the lower cover 120 is attached.

Referring to FIGS. 1A and 1B, the body 110 includes a floor 140, innerside walls 160, and outer side walls 170. The inner side walls 160 andthe inner side walls 170 are joined at rims 165 of the body 110. Thefloor 140 and the inner side walls 160 of the body 110 define theinterior space 112 of the body 110 to receive the item and optionally acoolant, e.g., ice, dry ice or a gel pack.

As noted above, the body 110 (whether a single-piece body or a shellthat encloses air or a core material) can include one or moreprojections that project inwardly from the floor or side walls of thebody 110. The inward projections can serve to hold the item in theinterior space 112, to divide the interior space 112 into separatesub-compartments, or to provide increased structural support for thebody 110.

For example, as shown in FIGS. 1N and 1O, an interior space of a coolercan be divided into two compartments 112 a, 112 b by a wall 190. Thispermits one compartment to be used for frozen items and the othercompartment to be used for refrigerated items. For example, frozen gelpacks can be placed in one compartment and refrigerated gel packs couldbe placed in the other compartment. These compartments 112 a, 112 b canbe completely closed off or have a through slot to allow for thermaltransfer. The wall 190 can be provided by interior side walls 160 a thatextend upwardly from the floor 140 of the shell and are connected by arim portion 165 a.

The body 110 can also include one or more projections that projectoutward from the floor or side walls of the body 110. The outwardprojections can provide increased structural support or for cushioningof the packaging.

The body 110 can also include one or more recesses in the interiorsurfaces of the side walls or floor. The recesses can serve to hold theitems being shipped, or to hold a coolant 260, e.g., ice, dry ice or agel pack, or to provide increased structural support for the body 110.In some situations, the recesses are simply the result of spaces betweenthe projections that are present for other purposes.

Where the body includes a shell, the protrusions on one side of theshell correspond to the recesses on the other side of the shell. Forexample, projections from the inner surface that extend inwardly intothe interior space 112 correspond to complementary recesses on the outersurface. Similarly, projections from the outer surface that extendoutwardly correspond to complementary recesses on the inner surface.

FIGS. 1F to 1H are perspective views of implementations of a thermallyinsulating packaging and show example shapes of the projections 181.

In FIG. 1F, the projections 181 are parallel rectilinear stripes. Theprojections 181 extend vertically on the inner surface of the side walls169. The projections 181 extend horizontally on the inner surface of thefloor 140. The spaces between the projections 181 provide grooves forair flow to improve uniformity of flow of cold air across the item heldin the interior space 112.

FIG. 1G illustrates a lid to fit on the top of the tub of FIG. 1F.Again, the spaces between the projections 181 provide grooves for airflow to improve uniformity of flow of cold air across the item held inthe interior space 112. In FIG. 1G, the projections 181 can have thesame dimensions and spacing as the projections 181 in FIG. 1F. Thispermits the grooves in the “tub” of FIG. 1F to line up with the groovesin the lid of FIG. 1G.

In FIG. 1H, the projections 181 combine to define a circular recessedarea, e.g., to receive a bottle. For example, individual projections canhave concave vertical surfaces; the provision of multiple suchprojections with the concave surfaces spaced around a central axis canthus define the circular recessed area.

The stippling shown in the bottom views of FIGS. 1F and 1H indicatesthat the cavity 180 between the walls 160, 170 and below the floor 140can be filled with the core material, e.g., a loose-fill compostable orrecyclable material. Similarly, the stippling shown in the bottom viewsof FIG. 1G indicates that a cavity between the walls 160, 170 and belowthe floor 140 that form the cover can be filled with the core material,e.g., a loose-fill compostable or recyclable material.

The structures of the projections 181 of the body 110 are described ingreater detail with reference to FIGS. 2A-4B.

In some implementations, the body 110 includes one or more pads 150 on alower surface of the floor 140. If the lower cover is present, the pads150 can contact the lower cover 120 and thus support the floor 140 ofthe body 110 above the lower cover 120. This maintains a gap between thefloor 140 and the lower cover 120. The gap can be filled with athermally insulating material, e.g., the core material as discussedabove. If the lower cover 120 is absent, the pads 150 can rest on thesurface supporting the packaging. This maintains a gap between the floor140 and the surface supporting the packaging

The pads 150 can absorb shock when the thermally insulating packaging100 is placed on ground or stacked on top of other shipping packages.

The pads 150 can be continuously jointed to the outer surface of thefloor 140 and be formed of the same material with the body 110. The pads150 can have any suitable shapes to absorb shock. For example, the pads150 can have a cross shape as illustrated in FIG. 1A, a circular shape,or a rectangular shape. The pads 150 can have a thickness, e.g., 0.5 to4 inches. The bottom of the pads 150 can be coplanar with the bottom ofthe outer side walls 160.

FIG. 1E is a bottom view of a floor a fourth implementation of athermally insulating packaging. The thermally insulating packaging 100includes the pads 150 and outer protrusions 152 on the outer surface ofthe floor 140. The pads 150 and the outer protrusions 152 arecontinuously joined to the outer surface of the floor 140 and areprimarily formed of the same material with the body 110.

The pads 150 and the outer protrusions 152 can be arranged various ways.For example, the pads 150 and the outer protrusions 152 can bealternately arranged. In addition, two adjacent pads 150 and twoadjacent outer protrusions 152 can be diagonally arranged. Adjacent pads150 and protrusions 152 can be connected by struts 156, which areadditional protrusions that are shorter than the pads 150 andprotrusions 152. These struts 156 provide improved structural supportfor the packaging 100. In some implementations, the struts 156 can havethe same height with the pads 150 or the protrusions 152.

The pads 150 can have any suitable shapes to absorb shock as describedabove. The outer protrusions 152 can also have any suitable shapes basedon a shape of the projections. For example, where the projections aredesigned to hold bottles, as illustrated in FIG. 1E, the recesses on theinner side of the body that are complementary to the outer protrusions152 can have a circular shape to bottles.

In some implementations, the pads 150 can be separately formed and beattached to the body 110. In these implementations, the pads 150 can beformed of a different material from the material used for the body 110.For example, the pads 150 can be formed of a material that provides morecushion to the body 110 than the material used for the body 110.

In some implementations, the bottom of the thermally insulatingpackaging 100 is closed off by a lower cover 120 to cover the cavity 180or material, e.g., the material of the core 182, in the cavity 180.

Referring to FIGS. 1A and 1B, the thermally insulating packaging 100 caninclude a separate cover 120 that is primarily formed of a compostableor recyclable material(s). The cover 120 can enclose the inner surfaceof the floor 140 and the space 180 of the body 110. In someimplementations, the cover 120 can be snuggly fit to bottom rims 155 ofthe outer side walls 160. In some other implementations, the cover 120can include grooves or protrusions on edges of the cover 120 to becoupled with the body 110. Example methods of coupling the cover 120 tothe body 110 are described in greater detail with reference to FIGS. 5Ato 5D.

FIG. 1C is a cross-sectional view of a second implementation of thethermally insulating packaging. In this example, the thermallyinsulating packaging 100 does not include a separate cover 120. Portions162 of the outer side walls 160 are hinged at a joint 164 of the outerside walls 160. The portions 162 provide flaps to cover the innersurfaces of the floor and the space 180 of the body 110. Although FIG.1C illustrates two flaps, there could be just one flap.

In some implementations, the outer and/or inner surfaces of the outerwalls 160, the inner walls 170, and the floor 140 can be optionallycovered by a moisture barrier layer 130 and/or 132. Details of thelayers 130, 132 are described in greater detail below.

In some implementations, referring to FIGS. 1J and 1K, the surfaces ofthe floor 140 and the side walls, e.g., inner side walls 160, that arecloser to the interior space 112 are covered by a moisture barrier layer132. The moisture barrier layer can be formed of the same material andhave the thickness with the moisture barrier layer 130 discussed below.The moisture barrier layer 132 can extend over just the inner surface ofthe floor 140 and inner walls 160, or also extend over the rim and/orouter walls 170, as shown in FIGS. 1L and 1M.

In some implementations, referring to FIGS. 1B and 1C, e.g., where thebody provide as shell with a gap between inner walls 160 and outer walls170, the surfaces of the walls 160, 170 that are closer to the cavity180 are covered by a moisture barrier layer 130.

In some implementations, referring to FIGS. 1L and 1M, both the surfacesadjacent the interior space 112 and the surfaces closer to the cavity180 are covered by the moisture barrier layers 130, 132. Although FIGS.1L and 1M show the moisture barrier layer 130 on the interior surface,as noted above this is optional; only the outer moisture barrier layer132 could be present.

As illustrated in FIG. 1A, when the cover 120 is coupled to the body110, the bottom of the body 110 is covered by the cover 120 and the topof the body 110 includes an opening to the interior space 112.

In some implementations, the interior space 112 can be covered by a lid.The lid can be primarily formed of a compostable or recyclablematerial(s). In some other implementations, the interior space 112 canbe covered by another thermally insulating article, so that together thetwo articles for the thermally insulating packaging. Examples ofcovering the interior space by a thermally insulating article aredescribed with reference to FIGS. 2A to 4B.

As noted above, in some implementations, the thermally insulatingpackaging 100 includes one or more protrusions that extend from one ormore of the inner sidewall(s) 170 and/or the floor 140 into the interiorspace 112. For example, the protrusion can include a wall or strut thatsections the interior space 112 into separate subspaces; this may beuseful for restraining items to be shipped or for increasing structuralstrength of the body. As another example, the protrusion can be a bumpor dimple; this may be useful for restraining or cushioning items in theinterior space 112.

Inner Structure of Thermally Insulating Packaging I

FIG. 2A is a perspective view of a first implementation of thermallyinsulating packaging. FIG. 2B is a cross-sectional view of a firstimplementation of thermally insulating packaging. The thermallyinsulating packaging 210, 220 can be the example thermally insulatingpackaging 100 described with reference to FIG. 1.

The first thermally insulating packaging 210 includes a first floor 219,first inner side walls, and first outer side walls 230. Detailsregarding the first floor 219, the inner side walls, and the first outerside walls 230 of the thermally insulating packaging 210 of FIG. 2A,e.g., overall structures, dimensions, and possible material compositionsfor the compostable materials, can be the same as the thermallyinsulating packaging 100 described with reference to FIG. 1.

The thermally insulating packaging 210 further includes the firstprojection 211. In FIG. 2A, the thermally insulating packaging 210 isillustrated as including one first projection 211. However, in someimplementations, the thermally insulating packaging 210 can includemultiple first projections on an inner surface of the first floor 219.The first projection 211 includes side walls 231 to hold the item. Forexample, the side walls 231 can be curved to effectively hold an itemthat has a curved surface, e.g., a bottle. The side walls 231 and afloor of the first projection 211 define an interior space 216 of thefirst projection 211. The item is accommodated in the interior space216.

Referring to FIG. 2B, some portions of the item 1 are accommodated inthe interior space 216 of the first projection 211 and other portions ofthe item 1 are accommodated in the interior space 226 of the secondprojection 212. In particular, the first projection 211 holds a firstportion of the item 1. In some implementations, the first projection 211can include a groove 235 on the floor of the first projection. Inparticular, where the item 1 has a narrow portion, e.g., a bottle neck,the groove 235 can help the narrow portion of the item fit snugly in theinterior space 216 of the first projection 211. In some implementations,the first projection 211 and the second projection 221 can be symmetric.In some implementations, the first projection 211 and the secondprojection 221 are not symmetric. For example, the interior space 216can have a shape different from that of the interior space 226 and/orthe groove 235 can have a shape different from that of the groove 228.

Referring back to FIG. 2A, the first projection 211 is located in thefirst interior space 218 defined by the floor 219 and the side walls230. In some implementations, the first projection 211 is continuouslyjoined to the floor 219 and the inner surfaces 264 of the side walls 230and is primarily formed of the same material with the thermallyinsulating packaging 210.

In some implementations, the first projection 211 can include one ormore grooves 214 on the curved side walls of the first projection 211.The grooves 214 helps cold air cooled by a coolant 260 efficientlyspread out in the interior space 218. In particular, the grooves 214 canincrease the surface area of the item contacting cold air so thatmaterials inside the item, e.g., a liquid, such as milk, fruit juice, orwine, in a bottle, or the item itself, e.g., packed meat or fish, canmaintain freshness.

In some implementations, the first thermally insulating packaging 210can include a protrusion 215 on the outer surface of the outer side wall230. The protrusion 215 can have the same or a smaller height than theheight of the outer side wall 230. The protrusion 215 can have box-likeshape, e.g., a generally rectilinear prism. In some implementations, theedges of the protrusion 215 can be rounded, while remaining a generallyrectilinear prism. The protrusion 215 can protect the first thermallyinsulating packaging 210 from being hit by other boxes in lateraldirections. For example, when the first thermally insulating packaging210 is placed with other boxes laterally, the protrusion 215 can keep agap between the first thermally insulating packaging 210 and other boxessuch that other boxes cannot directly hit the side walls 230 of thefirst thermally insulating packaging 210.

In some implementations, the first thermally insulating packaging 210can include a groove 217 on the outer surface of the outer side wall 230that is shaped for a hand grip. The groove 217 can be located on one ofthe bottom edges of the side walls 230. A user can insert his or herhand into the groove 217 to carry the first thermally insulatingpackaging 210 easily.

The second thermally insulating packaging 220 includes a second floor,second inner side walls, second outer side walls 240, and a secondprojection 222. The second thermally insulating packaging 220 canfurther include a protrusion 225 and a groove 227 for a hand grip.Details regarding the second floor, the second inner side walls, thesecond outer side walls 240, the second projection 222, the protrusion225, and the groove 227 of the second thermally insulating packaging220, e.g., overall structures, dimensions, and possible materialcompositions for the compostable materials, can be the same as the firstthermally insulating packaging 210.

The second thermally insulating packaging 220 further includes sidewalls 235 on inner surfaces of the outer side walls 230. The side walls235 have the height that is smaller than the height of the outer sidewalls 230. Thus, the second thermally insulating packaging 220 includestwo rim portions 222, 223 in a different level. On the other hand, thefirst thermally insulating packaging 210 further includes protrusions212 on the rims 213 of the side walls 230.

In FIG. 2A, if the first thermally insulating packaging 210 is turnedover and is placed on top of the second thermally insulating packaging220, the rims 213 of the first thermally insulating packaging 210 arecoupled to the rims 223 of the second thermally insulating packaging 220and the protrusions 212 of the first thermally insulating packaging 210are coupled to the rims 222 of the second thermally insulating packaging220. As a result, the first thermally insulating packaging 210 can becoupled to the second thermally insulating packaging 220. The coupledpackagings 210, 220 can be shipped as a single shipping package 200. Inthis example, the protrusion 215 of the first thermally insulatingpackaging 210 can align with the protrusion 225 of the second thermallyinsulating packaging 220.

In some implementations, the first thermally insulating packaging 210,the second thermally insulating packaging 220, or both of them caninclude a groove or slot 229 to accommodate a coolant 260. For example,in FIG. 2A, a portion of the side walls 235 has the groove or slot 229to accommodate the coolant 260. The second thermally insulatingpackaging 220 can spread cold air cooled by the coolant 260 so thatmaterials being shipped can maintain freshness. Optionally, the grooveor slot 229 can have a holding mechanism to hold the coolant 260 so thatthe coolant 260 can be fixed while the first thermally insulatingpackaging 210 is shipped.

In some implementations, as described above, the first thermallyinsulating packaging 210 can include multiple first projections 211. Inthese implementations, the first thermally insulating packaging 210 caninclude one or more grooves or slots between the adjacent firstprojections 211 to accommodate the coolant 260.

In some implementations, the first projection 211 can be separatelyformed and be attached to the floor 219 and the inner surfaces 264 ofthe side walls 230. In these implementations, the first projection 211can be formed of a different material from the material used for thethermally insulating packaging 210. For example, the first projection211 can be formed of a material that provides more cushion to the itemthan the material used for the body 110.

FIG. 2C is a perspective view of a second implementation of a set ofthermally insulating packagings that form a thermally insulatingshipping package. The thermally insulating shipping package 200 includesthe first thermally insulating packaging 210, the second thermallyinsulating packaging 220, and one or more thermally insulating extenders280, e.g., up to ten extenders.

Each extender 280 generally takes the form of an annular body that isopen at the top and the bottom. The extender 280 can have a generallyrectangular perimeter. Of course, the edges of the body can be rounded,while remaining a generally rectangular. In addition, the extender couldhave other shapes, e.g., octagonal, cylindrical, etc.

For example, the extender in FIG. 2C includes a first opening 281, asecond opening 282, side walls defining the first opening and the secondopening, and first rims 288, and second rims 286. The first rims 288 arecoupled to the rims 213 of the first thermally insulating packaging 210and the second rims 286 are coupled to the rims 223 of the secondthermally insulating packaging 220. As a result, the first thermallyinsulating packaging 210, the extender 280, and the second thermallyinsulating packaging 220 can form the single shipping package 200.Coupling mechanisms between the extender 280 and the thermallyinsulating packagings 210, 220 are described in greater detail withreference to FIG. 5A to 5D.

FIG. 2D is a cross-sectional view of the set of articles of FIG. 2C. Theextender 280 couples two thermally insulating packagings 210, 220 suchthat the interior space 282 can be extended. In some implementations,multiple extenders can be coupled between the first thermally insulatingpackaging 210 and the second thermally insulating packaging 220. Thus,the interior space 282 of the shipping package 200 can be extended asmuch as a user wants.

Optionally, as shown in FIG. 2E, one of the pieces of the thermallyinsulating packaging 200, e.g., the lower section 220, can include oneor more recesses 285, in which projections 284 on the top surface of therim 287 of the lower section 220 will fit. This permits the lowersection 220 to act as a stackable tray, with multiple lower sectionsstacked vertically. The recesses 285 can be a cut-out on the edges ofthe packaging 220 or grooves formed on the underside of the packaging220. Having the projections 284 inserted into the recesses 285 assistsin stability of the overall packaging 100, e.g., if packaging 200 ismoved then it is less likely that the individual trays will slide ortopple.

In addition, the thermally insulating packaging 220 can include one ormore slots 283 on the floor of the thermally insulating packaging 220 todischarge liquid from the interior area 282 to an exterior area of thethermally insulating packaging 220. For example, condensed liquid in theinterior can be discharged through the slots 283.

Inner Structure of Thermally Insulating Packaging II

FIG. 3A is a perspective view of a second implementation of thermallyinsulating packaging. FIG. 3B is a cross-sectional view of a secondimplementation of thermally insulating packaging. The thermallyinsulating packaging 310, 320 can be the example thermally insulatingpackaging 100 described with reference to FIG. 1.

The first thermally insulating packaging 310 includes a first floor 319,first inner side walls, and first outer side walls 330. Detailsregarding the first floor 319, the inner side walls, and the outer sidewalls 330 of the thermally insulating packaging 310 of FIG. 3A, e.g.,overall structures, dimensions, and possible material compositions forthe compostable materials, can be the same as the first thermallyinsulating packaging 210 described with reference to FIG. 2A.

The thermally insulating packaging 310 further includes the firstprojections 311. The first projections 311 protrudes from inner surfacesof the outer side walls 330 and/or the floor 319. For example, each ofthe first projections 311 can have a box-like shape, e.g., a generallyrectilinear prism. In some implementations, the edges of the protrusion315 can be rounded, while remaining a generally rectilinear prism. Thefirst projections 311 can extend in parallel each other to define agroove 316 between two adjacent first projections 311.

In some implementations, the grooves 316 are shallow, and primarilyserve to provide for air flow such that cold air can reach all aroundthe item being shipped.

In some implementations, referring to FIG. 3B, the first projections 311can hold the item 1 in the groove 316. A portion of the item 1, e.g., abottle, can be accommodated in the groove 316. In some implementations,referring to FIG. 3C, the first projections 311 hold the item 1 in theinterior space 318. The interior space 318 is a space defined by thefloor 319 and the outer side walls 330 of the first thermally insulatingpackaging 310. A portion of the item, e.g., a meat package, can beaccommodated in the interior space 318. In these implementations, thegroove 316 helps cold air cooled by a coolant 360 efficiently spread outin the interior space 318. In particular, the groove 316 can maximizesurface of the item contacting cold air so that materials, e.g., juiceor wine, inside the item, e.g., a bottle, or the item itself, e.g.,packed meats or fishes, can maintain freshness.

In some implementations, referring to FIG. 3D, the thermally insulatingpackagings 310, 320, 330 include the projections 311, 321, 331 on boththe top surface and the bottom surface of the thermally insulatingpackagings 310, 320, 330. When each of the thermally insulatingpackagings 310, 320, 330 are stacked, multiple items 1 can be stored inthe spaces 316, 326 between the adjacent packagings. It can increase thestoring capacity.

Referring back to FIG. 3A, in some implementations, the firstprojections 311 can be part of the thermally insulating packaging 310and be primarily formed of the same material with the thermallyinsulating packaging 310. In some other implementations, the firstprojections 311 can be separately formed and be attached to thethermally insulating packaging 310. In these implementations, the firstprojections 311 can be formed of a different material from the materialused for the thermally insulating packaging 310. For example, the firstprojections 311 can be formed of a material that provides more cushionto the item than the material used for the second thermally insulatingpackaging 310.

Like the first thermally insulating packaging 210 described withreference to FIG. 2A, the first thermally insulating packaging 310 caninclude a protrusion 315 and a groove 317. Details regarding theprotrusion 315 and the groove 317 of the thermally insulating packaging310 of FIG. 3A, e.g., overall structures, dimensions, and possiblematerial compositions for the compostable materials, can be the same asthe first thermally insulating packaging 210 described with reference toFIG. 2A.

Furthermore, details regarding the second thermally insulating packaging320 and a single shipping package 300, e.g., overall structures,dimensions, and possible material compositions for the compostablematerials, can be the same as the second thermally insulating packaging210 and the single shipping package 200 described with reference to FIG.2A.

Inner Structure of Thermally Insulating Packaging III

FIG. 4A is a perspective view of a third implementation of thermallyinsulating packaging. FIG. 4B is a cross-sectional view of a thirdimplementation of thermally insulating packaging. The thermallyinsulating packagings 410, 420 can be the example thermally insulatingpackaging 100 described with reference to FIG. 1.

The first thermally insulating packaging 410 includes a first floor,first inner side walls, and first outer side walls 430. Detailsregarding the first floor, the inner side walls, and the outer sidewalls 430 of the thermally insulating packaging 410 of FIG. 4A, e.g.,overall structures, dimensions, and possible material compositions forthe compostable materials, can be the same as the first thermallyinsulating packaging 210 described with reference to FIG. 2A.

The thermally insulating packaging 410 further includes the firstprojection 411. In FIG. 4A, the thermally insulating packaging 410 isillustrated as including one first projection 411. However, in someimplementations, the thermally insulating packaging 410 can includemultiple first projections on an inner surface of the first floor. Thefirst projection 411 includes side walls 431 to hold the item. Forexample, the side walls 431 can be curved to hold the item that has acurved surface efficiently. The side walls 431 and a floor of the firstprojection 411 define an interior space 416 of the first projection 411.The item is accommodated in the interior space 416. Referring to FIG.4B, some portions of the item 1 are accommodated in the interior space416 of the first projection 411 and other portions of the item 1 areaccommodated in the interior space 426 of the second projection 412.

In some implementations, the first projection 411 can include one ormore grooves 414 on the curved side walls of the first insert 411. Thegrooves 414 helps cold air cooled by a coolant 460 efficiently spreadout in the interior space 418. In particular, the grooves 414 canmaximize surface of the item contacting cold air so that materials,e.g., juice or wine, inside the item, e.g., a bottle, or the itemitself, e.g., packed meats or fishes, can maintain freshness.

Like the first thermally insulating packaging 210 described withreference to FIG. 2A, the first thermally insulating packaging 410 caninclude a protrusion 415 and a groove 417. Details regarding theprotrusion 415 and the groove 417 of the thermally insulating packaging410 of FIG. 4A, e.g., overall structures, dimensions, and possiblematerial compositions for the compostable materials, can be the same asthe first thermally insulating packaging 210 described with reference toFIG. 2A.

Furthermore, details regarding the second thermally insulating packaging420 and a single shipping package 400, e.g., overall structures,dimensions, and possible material compositions for the compostablematerials, can be the same as the second thermally insulating packaging210 and the single shipping package 200 described with reference to FIG.2A.

Cover

FIG. 5A is a cross-sectional view of a first implementation of a coverto a thermally insulating packaging. The thermally insulating packaging100 includes the body 110 and the cover 120. The cover 120 includesgrooves 31 on the edges of the cover 120. The body 110 includesprotrusions on the rims 155 of the outer side walls 160. The protrusions32 of the body 110 can be coupled to the grooves 31 of the cover 120such that the cover 120 can be firmly coupled to the body 110 by thefriction between the grooves 31 and the protrusions 32.

FIG. 5B is a cross-sectional view of a second implementation of a coverto a thermally insulating packaging. The thermally insulating packaging100 includes the body 110 and the cover 120. The cover 120 can becoupled to the body 110 using an adhesive.

FIG. 5C is a cross-sectional view of a third implementation of a coverto a thermally insulating packaging. The thermally insulating packaging100 includes the body 110 and the cover 120. The cover 120 includesprotrusions 41 adjacent to the edges of the cover 120. The body 110includes grooves 42 on the rims 155 of the outer side walls 160. Theprotrusions 41 of the cover 120 110 can be coupled to the grooves 42 ofthe body 110 such that the cover 120 can be firmly coupled to the body110 by the friction between the grooves 42 and the protrusions 41.

FIG. 5D is a cross-sectional view of a fourth implementation of a coverto a thermally insulating packaging. The thermally insulating packaging100 includes the body 110 and the cover 120. The cover 120 includesprotrusions 53 adjacent to the edges of the cover 120. The body 110includes protrusions 52 on the rims 155 of the outer side walls 160.When the cover 120 is placed to cover the body 110, side surfaces of theprotrusions 52 are coupled to side surfaces of the protrusions 53 suchthat the cover 120 can be firmly coupled to the body 110 by the frictionbetween the protrusions 52 and the protrusions 53.

The cover 120 can be made of compostable materials. In someimplementations, the cover 120 can be made of the same compostablematerial that is used for the body 110. In some other implementations,the cover 120 can be made of a compostable material that is differentfrom the compostable material used for the body 110.

Similar to the body 110, the cover 120 can be a single-piece panelformed of the compostable material, or can include a shell ofcompostable material that at least partially encloses a core ofcompostable material.

In some implementations, the cover 120 has a length and a width thatmatch the bottom of the body 110.

In some implementations, a water-proof, water-resistant orwater-repellant layer can fully enclose the cover 120. For example, thelayer can enclose all the surfaces of the cover 120. In some otherimplementations, the layer can enclose the cover 120 in part. Forexample, the layer can enclose a particular surface, e.g., an interiorsurface or an exterior surface, of the cover 120 or a portion of aparticular surface, e.g., a bottom portion or an upper portion of theinterior surface, of the cover 120.

The coupling mechanisms described with reference to FIGS. 5A to 5D canbe also used to couple two thermally insulating packagings describedwith reference to FIGS. 2A, 3A and 4A or to couple the extender 280 tothe thermally insulating packagings 210, 220 described with reference toFIGS. 2C and 2D.

Manufacturing Process

FIG. 6 is a diagram illustrating an example system to manufacture thethermally insulating packaging 100 of FIG. 1A.

As described above, the thermally insulating packaging 100 includes thesolid compostable or recyclable body 110 and optionally the layer 130.The system 500 manufactures the thermally insulating packaging 100 usingtwo processes, (i) a process to form the body 110 and (ii) a process toaffix the layer 130 on a surface of the body 110. To form the body 110,any suitable techniques can be used. For example, a suction techniquecan be used. To affix the layer 130 on a surface of the body 110, anysuitable techniques can be used. For example, an adhesive can be used.

The system 200 includes a mold 510, a pump 520, a spray 530, and one ormore pipes 540. In this example suctioning process, compostable materialthat is provided to the mold 510 described above is provided to thereservoir 210. The compostable material can be highly viscous. Once thecompostable material is provided on the surfaces of the mold 510, thepump 520 sucks the compostable material through the pipes 540 such thatthe compostable material evenly spreads over the surfaces of the mold510. When the suction process is completed, the compostable materialbecome hardened. Additional cooling or curing can be applied if neededto harden the compostable material. As a result, the body 110 is formed.

Optionally, the system 200 can affix the layer 130 on a surface of theunitary body 110. In this example, the layer 130 encloses the entireinner surfaces of the unitary body 110. In some implementations,different techniques can be used to partially enclose the unitary body110 using the layer 130.

In some implementations, the layer can be secured to the body 110 by anadhesive. The adhesive can be a separate additive, or the adhesive canbe provided by applying water to the body 110 to cause the starch in aportion of the body 110 at the surface to become tacky such that thelayer 130 sticks to the body 110.

Where both the body 110 and layer 130 are compostable, the entirethermally insulating packaging 100 can be disposed of as a unit in acomposting bin. Where the body 110 is compostable and the layer 130 isrecyclable, the layer can be ripped off the body 110 manually by therecipient of the package, and then the body 110 can be disposed of in acomposting bin and the layer can be disposed of a recycling bin.

Stackable Compostable or Recyclable Body

FIGS. 7A to 7C are cross-sectional views of implementations of astackable body. In FIG. 7A, the outer side walls 160 can have a slope ata certain angle between 0 and 90 degrees. In FIG. 7B, the rims 165 ofthe outer side walls 160 are curved. In FIG. 7C, the outer side walls160 have a slope and does not have rims between the outer side walls 160and the inner side walls 170. These shapes of the body 110 enablesmultiple compostable bodies 110 to be stackable. As a result, largenumbers of compostable bodies can be stacked so that they can be easilymoved. In addition, the multiple compostable bodies can be stacked, theyrequire less storage space.

Moisture Barrier Layer

The moisture barrier layer 130 can be water-proof, water-resistant orwater-repellant layer 130 that encloses at least a portion of thecompostable body 110. In some implementations, the layer 130 can fullyenclose the compostable body 110. For example, the layer 130 can encloseacross the entire surfaces of the compostable body 110. In some otherimplementations, the layer 130 can only partially enclose thecompostable body 110. For example, the layer 130 can cover a particularsurface, e.g., an interior surface or an exterior surface, of thecompostable body 110 or a portion of a particular surface, e.g., aperimeter portion along the edge, a bottom portion, a central portion,or an upper portion of the interior surface, of the compostable body110.

The layer 130 can be a biodegradable or compostable layer. The layer 130prevents or inhibits water from penetrating the layer 130 not only fromthe interior area 35 to an exterior area of the compostable body 110,but also from the exterior area to the interior area 35. In someimplementations, the layer 130 can be air-tight. In someimplementations, the layer 130 can be a plastic film.

In some implementations, the layer 130 can be compostable, e.g., abioplastic that meets ASTM D6400 standards. Example materials for acompostable layer include polymers based on one or more of polylacticacid (PLA), poly(beta-amino) esters (PBAE), polyhydroxyalkanoate (PHA),polycapralactones (PCL), polybutyrate adipate terephthalate (PBAT)polyvinylalcohol (PVA), or ethylene vinyl alcohol (EVOH). In addition,any combinations of these materials can be used for the layer 130. Forexample, a combination of PBAT and PE can be used for the layer 130. Asanother example, a combination of PE and PLA can be used for the layer130. In some implementations, the polymer can be mixed with an organicproduct, e.g., starch or pulp, such as corn starch.

In some implementations, the layer 130 can be recyclable andbiodegradable. A suitable material for the recyclable layer ispolyethylene, e.g., a polyethylene film. For example, the layer caninclude LDPE, MDPE, HDPE, or polyethylene terephthalate. An advantage ofpolyethylene is ease of fabrication and good water resistance.

In some implementations, the layer is a paper sheet. If the paper isthin enough or is perforated, the paper is compostable. Optionally, thepaper can be lined with a water-repellant coating. Either the innersurface of the layer, or the outer surface, or both can be lined withthe water-repellant coating. The water-repellant coating can be acompostable material, e.g., wax. In this case, the layer with paper andcoating is compostable. Alternatively, the water-repellant coating canbe a recyclable material. In this case, the layer with paper and coatingis recyclable.

In some implementations, the layer provides a film that encloses thecompostable body, e.g., the body is slidable within a pocket formed bythe film. In some implementations, the film is secured to thecompostable body 110 by an adhesive.

In some implementations, the layer directly coats the compostable body.The layer that directly coats the compostable body can be composed of anorganic compostable material, e.g., a wax. The layer can be spread in athin layer on the surface of the body. The layer can be applied inliquid form and then harden on the compostable body. Alternatively, thelayer can be sprayed onto the body. The sprayed-on layer can provide amoisture barrier. For example, a water-proof, water-resistant orwater-repellant material can be sprayed onto the panel. In someimplementations the layer can be polylactic acid (PLA).

A problem with starch-based insulation is that it dissolves easily inwater. If the item being shipped is cold or a coolant is placed in theinterior of the shipping container 10, condensation can form on theinterior surfaces of the thermally insulating packaging 100. However,the layer 130 prevents liquid, e.g., the condensation, from reaching thestarch of the compostable body 110, thus enabling the thermallyinsulating packaging 100 to be usable as a thermal insulator in theshipping container 10. However, in some implementations, the compostablebody 110 is exposed to the environment, i.e., there is no layer coatingor surrounding the compostable body 110.

Conclusion

It should be understood that, although various terms such as “top”,“bottom”, “vertical,” and “lateral” are used, these terms indicaterelative positioning of components under the assumption that an openingto the box 20 is at the top, and don't necessarily indicate anorientation relative to gravity; in use, or even during assembly, thecontainer 10 could be on its side or upside down relative to gravity.The term “slightly” indicates no more than about 5%, e.g., no more than2%.

A variety of combinations of the features discussed above are possible.The drawings show only a limited number of possible combinations, and itshould be assumed that the various features described can be usedtogether in any consistent combination. For example, the moisturebarrier could coat the inside, or the inside and outside, of the singlepiece body (e.g., the body 110 shown in FIG. 1D). As another example,the recesses for air flow (e.g., as shown in FIG. 1F) could be combinedwith any of the other implementations. The 132 illustrated on the shellin any could be coat of FIG

A number of embodiments have been described. Nevertheless, it will beunderstood that various modifications may be made without departing fromthe spirit and scope of the invention. Accordingly, other embodimentsare within the scope of the following claims.

What is claimed is:
 1. A cooler to hold an item, the cooler comprising:a solid compostable or recyclable body that is formed primarily of acombination of starch and plant fiber, wherein the body includes: afloor, a plurality of side walls that are continuously and seamlesslycoupled to the floor along first common edges and each continuously andseamlessly coupled to two adjacent side walls along second common edges,wherein the floor and the plurality of side walls define an interiorspace of the body to receive the item and an opening to the interiorspace, wherein the side walls include a plurality of protrusionsextending inwardly toward the interior space to provide increasedstructural support for the body while maintaining the interior space ofthe body as a single tub, and wherein the floor and side walls of thebody are at least 0.02 inch thick and have a uniform thickness such thatthe protrusions on the inner side of the side walls define complementaryrecesses on the outer side of the side walls.
 2. The cooler of claim 1,wherein at least 90% by weight of the body is the combination of starchand plant fiber.
 3. The cooler of claim 2, wherein at least 95% byweight of the body is the combination of starch and plant fiber.
 4. Thecooler of claim 3, wherein body consists of the combination of starchand plant fiber.
 5. The cooler of claim 2, wherein the body includes amoisture barrier material mixed with the combination of starch and plantfiber.
 6. The cooler of claim 5, wherein body consists of thecombination of starch, plant fiber and moisture barrier material.
 7. Thecooler of claim 6, wherein body consists of the combination of starch,plant fiber and polylactic acid.
 8. The cooler of claim 2, wherein thebody includes polylactic acid mixed with the with the combination ofstarch and plant fiber.
 9. The cooler of claim 1, wherein the plantfiber is a paper pulp.
 10. The cooler of claim 1, wherein the starch isa grain starch.
 11. The cooler of claim 1, comprising a moisture barrierlayer disposed on the shell and configured to block water penetratingthe shell.
 12. The cooler of claim 1, wherein a thickness of the body is1/32 to 1 inch.
 13. The cooler of claim 1, wherein a thickness of thebody is 0.02 to 0.3 inches.
 14. The cooler of claim 1, wherein therecess is shaped to provide a hand grip for the cooler.
 15. The coolerof claim 14, wherein the recess is positioned adjacent a horizontal edgeof the side wall.
 16. The cooler of claim 1, wherein each side wall oftwo opposite side walls of the plurality of side walls form a protrusionthat extends inwardly into the interior space.
 17. The cooler of claim1, wherein each protrusion runs vertically from near an upper edge ofthe side wall to the floor of the side wall.
 18. The cooler of claim 1,wherein the plurality of protrusions run vertically on the side walls.19. The cooler of claim 18, wherein the plurality of protrusions formrectilinear stripes.
 20. The cooler of claim 1, wherein the body iscompostable.
 21. The cooler of claim 1, wherein the body is recyclable.22. The cooler of claim 1, wherein the starch is a milled or extrudedstarch.